US10930613B2 - Semiconductor package having recessed adhesive layer between stacked chips - Google Patents
Semiconductor package having recessed adhesive layer between stacked chips Download PDFInfo
- Publication number
- US10930613B2 US10930613B2 US16/438,505 US201916438505A US10930613B2 US 10930613 B2 US10930613 B2 US 10930613B2 US 201916438505 A US201916438505 A US 201916438505A US 10930613 B2 US10930613 B2 US 10930613B2
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- semiconductor
- semiconductor chip
- adhesive layer
- semiconductor chips
- chips
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Definitions
- the present disclosure relates to a semiconductor package and a method of manufacturing the same.
- a semiconductor package includes a first semiconductor chip having a first through substrate via (TSV), a second semiconductor chip stacked on the first semiconductor chip and a first adhesive layer (e.g., non-conductive film) disposed between the first semiconductor chip and the second semiconductor chip.
- the second semiconductor chip includes a second through substrate via connected to the first through substrate via. A side surface of the first adhesive layer is recessed from side surfaces of the first and second semiconductor chips.
- a semiconductor package includes a base substrate having a wiring circuit, semiconductor chips stacked in a direction perpendicular to an upper surface of the base substrate, a first adhesive layer disposed between the base substrate and a lowermost semiconductor chip and second adhesive layers. A side surface of the first adhesive layer is recessed from a side surface of the lowermost semiconductor chip.
- Each adhesive layers is disposed between corresponding two adjacent semiconductor chips of the semiconductor chips and has a side surface recessed from side surfaces of the corresponding two adjacent semiconductor chips.
- a semiconductor package includes first and second semiconductor chips stacked in a vertical direction, and an adhesive layer disposed between the first semiconductor chip and the second semiconductor chip, each of the first and second semiconductor chips has a semiconductor substrate having a lower surface and an upper surface opposing each other, a semiconductor device layer disposed on the lower surface of the substrate, and a through silicon via penetrating the semiconductor substrate and the semiconductor device layer, the through substrate via of the first semiconductor chip is connected to the through substrate via of the second semiconductor chip, and a side surface of the adhesive layer is a concave surface recessed from side surfaces of the first and second semiconductor chips.
- a method of manufacturing a semiconductor package is provided as follows.
- Each of semiconductor chips and each of first uncured adhesive layers are alternately stacked on each other.
- the first uncured adhesive layers are cured at a first temperature under a first pressure so that the first uncured adhesive layers are cured to form first cured adhesive layers each of which a side surface is recessed from side surfaces of corresponding two adjacent semiconductor chips.
- the first pressure is formed by using a pressurized fluid.
- the first temperature is above a curing temperature of the first uncured adhesive layers.
- FIG. 1 is a cross-sectional view illustrating a semiconductor package according to example embodiments
- FIG. 2 is an enlarged cross-sectional view illustrating region “A” of FIG. 1 ;
- FIG. 3 is an enlarged cross-sectional view of a non-conductive film employed in a semiconductor package according to example embodiments
- FIG. 4 is a cross-sectional view illustrating a semiconductor package according to example embodiments
- FIG. 5 is a cross-sectional view illustrating a semiconductor package according to example embodiments.
- FIG. 6 is an enlarged cross-sectional view of region “B” of FIG. 5 ;
- FIG. 7 is a process flowchart illustrating a method of manufacturing a semiconductor package according to an example embodiment
- FIG. 8 is a curing temperature and pressure versus time graph illustrating a hydrostatic bonding process employed in a method of manufacturing a semiconductor package according to an example embodiment
- FIGS. 9 to 12 are cross-sectional views for describing a method of manufacturing a semiconductor package according to an example embodiment.
- FIG. 13 is a block diagram illustrating a configuration of a semiconductor package according to an example embodiment.
- FIG. 1 is a cross-sectional view illustrating a semiconductor package according to example embodiments.
- a semiconductor package 200 may include a first semiconductor chip 100 A, a second semiconductor chip 100 B, a third semiconductor chip 100 C, and a fourth semiconductor chip 100 D.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be electrically connected to semiconductor chips adjacent to each other through second to fourth connection bumps 170 B, 170 C, and 170 D.
- first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be bonded to each other by non-conductive films (or adhesive layers) 150 .
- a side surface CS of each of the non-conductive films 150 may be recessed from side surfaces of corresponding two adjacent semiconductor chips of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D.
- the side surfaces CS of the non-conductive films 150 may have concave surfaces.
- the side surfaces CS of the non-conductive films 150 may have different recessed depths. Such shapes may enhance the bond strength with a molding member or may prevent defects from being developed in a subsequent process following a process of stacking semiconductor chips, as will be more fully described hereinafter.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be memory chips or logic chips. In one example embodiment, the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may all be the memory chips of the same kind. In another example embodiment, some of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be memory chips and the others are logic chips. In a specific embodiment, the first semiconductor chip 100 A may be a logic chip, and the second to fourth semiconductor chips 100 B, 100 C, and 100 D may be memory chips.
- the memory chips may be volatile memory chips such as dynamic random access memory (DRAM) chips and static random access memory (SRAM) chips, or may be non-volatile memory chips, such as phase-change random access memory (PRAM) chips, magnetoresistive random access memory (MRAM) chips, ferroelectric random access memory (FeRAM) chips, and resistive random access memory (RRAM) chips.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be high bandwidth memory (HBM) DRAM.
- the logic chips may be, for example, microprocessors, analogue devices, or digital signal processors.
- the number of semiconductor chips that may be stacked in the semiconductor package 200 is not limited thereto. For example, two, three, or even more semiconductor chips (for example, eight chips) may be stacked in the semiconductor package 200 .
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be identical chips, and as illustrated in FIG. 1 , may have the same surface area. In some example embodiments, the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may have different surface areas. Not all side surfaces of the semiconductor chips may be aligned to be substantially coplanar, and for example, at least portions of the side surfaces of the semiconductor chips may have a step-like alignment.
- side surfaces of the non-conductive films may at least be recessed from the side surfaces of a semiconductor chip close to the center of the stack.
- Each of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may include a semiconductor substrate 110 , a semiconductor device layer 120 , a through substrate via (TSV) 130 , a lower connection pad 142 , an upper connection pad 144 , and first to fourth connection bumps 170 A, 170 B, 170 C, and 170 D.
- TSV through substrate via
- the fourth semiconductor chip 100 D, disposed uppermost, may not include a through substrate via 130 .
- the semiconductor substrate 110 of each of the semiconductor chips 100 A to 100 D may include an upper surface and a lower surface opposing the upper surface.
- the semiconductor device layer 120 may be provided on the lower surface of the semiconductor substrate 110 , and a wiring structure 140 may be provided within the semiconductor device layer 120 .
- the through substrate via 130 may penetrate the semiconductor substrate 110 to connect the upper surface and the lower surface of the semiconductor substrate 110 , thereby being connected to the wiring structure 140 .
- the lower connection pad 142 may be formed on the semiconductor device layer 120 and may be electrically connected to the through substrate via 130 through the wiring structure 140 .
- the through substrate via 130 may extend not only through the semiconductor substrate 110 , but may extend through the entire semiconductor chip ( 100 A, 100 B, 100 C or 100 D).
- the through substrate via 130 may be a through silicon via.
- the semiconductor substrate 110 of each of the semiconductor chips 100 A to 100 D may be formed of a crystalline semiconductor material.
- the semiconductor substrate 110 may be formed of a semiconductor material such as silicon and germanium, or a compound semiconductor material such as silicon carbide (SiC), gallium arsenide (GaAs), indium arsenide (InAs), and indium phosphide (InP).
- the semiconductor substrate 110 may have a silicon-on-insulator (SOI) structure.
- the semiconductor substrate 110 may include a buried oxide (BOX) layer.
- the semiconductor substrate 110 may include a conductive region, for example, a well doped with an impurity or a structure doped with an impurity.
- the semiconductor substrate 110 may include various device isolation structures, such as shallow trench isolation (STI) structures.
- STI shallow trench isolation
- the semiconductor device layer 120 may be formed to include the wiring structure 140 to connect each of individual devices to other wirings formed in the semiconductor substrate 110 .
- the wiring structure 140 may include a metal wiring layer and a via plug.
- the wiring structure 140 may be a multilayer structure in which two or more metal wiring layers or two or more via plugs are alternately stacked.
- the through substrate vias 130 may extend from the upper surface of the semiconductor substrate 110 towards the lower surface thereof, and may further extend into the semiconductor device layer 120 .
- the through substrate via 130 may partially penetrate the semiconductor device layer 120 to be connected to the wiring structure 140 .
- At least portions of the through substrate vias 130 may have the shape of a pillar.
- the semiconductor chip disposed at the uppermost level (for example, the fourth semiconductor chip 100 D) may not include the through substrate via 130 .
- the lower connection pad 142 may be disposed on the semiconductor device layer 120 and may be electrically connected to the wiring structure 140 within the semiconductor device layer 120 .
- the lower connection pad 142 may be electrically connected to the through substrate vias 130 through the wiring structure 140 .
- the lower connection pad 142 may include at least one of aluminum (Al), copper (Cu), nickel (Ni), tungsten (W), platinum (Pt), and gold (Au).
- a lower passivation layer (not illustrated) may be formed on the semiconductor device layer 120 to protect the wiring structure 140 within the semiconductor device layer 120 and the other structures disposed therebelow from external stress and humidity.
- the lower connection pad 142 may be partially exposed from the lower passivation layer to be connected to one of a corresponding connection bump of the first to fourth connection bumps 170 A to 170 D.
- the upper connection pad 144 may be formed on the upper surface of the semiconductor substrate 110 to be electrically connected to the through substrate vias 130 .
- the upper connection pad 144 may include the same material as the lower connection pad 142 .
- an upper passivation layer (not illustrated) may be formed on the upper surface of the semiconductor substrate 110 to surround portions of the through substrate vias 130 .
- Each of the first to fourth connection bumps 170 A, 170 B, 170 C, and 170 D may be disposed on a corresponding lower connection pad 142 of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, respectively.
- the first connection bump 170 A may be formed by a pillar structure, a ball structure, or a solder layer.
- the first connection bump 170 A may be disposed on the lower connection pad 142 of the first semiconductor chip 100 A so that the semiconductor package 200 is electrically connected to an external wiring circuit (for example, a base substrate 300 shown in FIG. 5 ).
- an external wiring circuit for example, a base substrate 300 shown in FIG. 5 .
- a control signal, a power signal, and a ground signal for operations of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be received from an external source; a data signal to be stored in the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, may be received from an external source; or data stored in the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, may be transmitted to the outside.
- the second semiconductor chip 100 B may be mounted on an upper surface of the first semiconductor chip 100 A.
- the second semiconductor chip 100 B may be electrically connected to the first semiconductor chip 100 A through the second connection bump 170 B, disposed between the first semiconductor chip 100 A and the second semiconductor chip 100 B.
- a first non-conductive film (or a first adhesive layer) 150 may be disposed to bond the second semiconductor chip 100 B to the first semiconductor chip 100 A.
- the third semiconductor chip 100 C may be mounted on an upper surface of the second semiconductor chip 100 B
- the fourth semiconductor chip 100 D may be mounted on an upper surface of the third semiconductor chip 100 C.
- the third connection bump 170 C and a second non-conductive film (or a second adhesive layer) 150 surrounding side surfaces of the third connection bump 170 C may be disposed.
- the fourth connection bump 170 D and a third non-conductive film 150 surrounding side surfaces of the fourth connection bumps 170 D, may be disposed.
- the molding member 180 may surround side surfaces of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, and side surfaces of the non-conductive films 150 . In some example embodiments, the molding member 180 may cover an upper surface of the fourth semiconductor chip 100 D. Alternatively, in other example embodiments, the molding member 180 may be formed to have the upper surface of the fourth semiconductor chip 100 D exposed externally (please refer to FIG. 4 ).
- the molding member 180 may include an epoxy mold compound (EMC) or the like.
- the non-conductive films 150 may be used as an interlayer bonding material in conjunction with the second to fourth connection bumps 170 B, 170 C, and 170 D.
- the semiconductor package manufacturing process may be conducted by reducing thicknesses of the non-conductive films, or by increasing viscosity of the non-conductive films.
- the non-conductive films may cause insufficient filling problems. Consequently, the semiconductor chips adjacent to each other may not be bonded to have a uniform thickness, or voids between the semiconductor chips may be developed in the non-conductive films 150 .
- the semiconductor package 200 may include the non-conductive films 150 having the side surfaces that are recessed from the side surfaces of the adjacent semiconductor chips 100 A, 100 B, 100 C, and 100 D. More specifically, the side surfaces of the non-conductive films 150 may have concave surfaces. The recessed or concave side surfaces of the non-conductive films 150 may be obtained by curing the non-conductive films 150 disposed between the stacked first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D through a hydrostatic bonding process using a pressurized fluid (for example, gas such as air or N 2 ).
- a pressurized fluid for example, gas such as air or N 2 .
- the non-conductive films 150 may be prevented from excessively overflowing to form overhangs and from having the insufficient filling problems at the same time. Accordingly, the bond strength between the molding member 180 and the non-conductive films 150 may be increased, thereby increasing the reliability of the semiconductor package.
- the non-conductive films 150 may serve to bond the stacked semiconductor chips 100 A, 100 B, 100 C, and 100 D.
- the non-conductive films 150 may include an adhesive resin.
- the adhesive resin may be a thermosetting resin.
- the adhesive resin may include, for example, at least one of bisphenol epoxy resin, novolac epoxy resin, phenol resin, urea resin, melamine resin, unsaturated polyester resin, and resorcinol resin.
- the non-conductive films 150 employed in the present example embodiment may have a relatively low viscosity so that recessed side surfaces of the non-conductive films 150 may be obtained.
- the non-conductive films 150 in an uncured state may have a viscosity equal to or less than about 1,000 Pa ⁇ s, wherein the viscosity is the minimum viscosity of the non-conductive films 150 and is a measurement taken at about 100° C.
- the measured temperature may have an error range of about ⁇ 5° C. at 100° C.
- the non-conductive films 150 may include a flux and/or a ceramic filler.
- the flux may be used in soldering to form an electrical bond between the semiconductor chips in the semiconductor package manufacturing process.
- the flux may increase spreadability and/or wettability of a solder, and the flux may be coated in advance on areas on which the solder will be coated, or may be included within the non-conductive films 150 .
- the flux may be classified as resin-based, organic, and inorganic, wherein the flux generally used in electronic devices may include a resin-based flux.
- the resin-based flux may include rosin, modified rosin, and synthetic resin.
- the ceramic filler depending on a particle size and a percentage thereof, may be used to adjust the viscosity of the non-conductive films.
- FIG. 2 is an enlarged cross-sectional view illustrating the region “A” shown in FIG. 1 .
- FIG. 2 illustrates a non-conductive film 150 located between the first and second semiconductor chips 100 A and 100 B.
- a side surface CS of the non-conductive film 150 may have a side surface recessed from between the semiconductor substrate 110 of the first semiconductor chip 100 A and the semiconductor device layer 120 of the second semiconductor chip 100 B.
- the recessed side surface CS may have a concave surface.
- the molding member 180 may have a region protruding into a recessed area between the first and second semiconductor chips 100 A and 100 B to be in contact with the side surface CS of the non-conductive film 150 .
- the recessed side surface CS may have a shape that is recessed from side surfaces of the first and second semiconductor chips 100 A and 100 B by a predetermined depth W.
- the bottom of the recessed side surface CS may be positioned at the predetermined depth W from the region between the first and second semiconductor chips 100 A and 100 B.
- the predetermined depth W of the molding member 180 may be relatively large in the region between the first and second semiconductor chips 100 A and 100 B.
- the non-conductive film 150 may overflow into neighboring regions (for example, side surfaces) of the semiconductor chips 100 A and 100 B in the semiconductor package manufacturing process.
- the non-conductive film 150 may be cured under pressure applied by the pressurized fluid during the hydrostatic bonding process to thus obtain the side surface CS recessed from the side surfaces of the first and second semiconductor chips 100 A and 100 B.
- the non-conductive film 150 may be compressed with the pressure applied by the pressurized fluid and internal voids in the non-conductive film 150 may be removed. Accordingly, the non-conductive film 150 may be more securely bonded with the connection bump 170 B and/or the first and second semiconductor chips 100 A and 100 B.
- Factors controlling the concave side surface CS of the non-conductive film 150 include the viscosity of the non-conductive film 150 in an uncured state and the processing conditions of a hydrostatic bonding process (for example, temperature, pressure, curing speed, etc.). Such processing conditions will be more fully described below.
- the recessed non-conductive film 150 between the first semiconductor chip 100 A and the second semiconductor chip 100 B may be formed without overhangs that may cause problems in a molding process, preventing defects due to the overhangs of the non-conductive film 150 and increasing the filling rate of the non-conductive film 150 .
- the filling rate may be increased by removing the voids in the non-conductive film 150 .
- the recessed non-conductive film 150 may increase the reliability of the semiconductor package 200 by enhancing the bond strength between the molding member 180 and the non-conductive film 150 .
- FIG. 3 is an enlarged cross-sectional view illustrating a non-conductive film employed in a semiconductor package according to another example embodiment.
- a recessed side surface CS′ of the non-conductive film 150 may have a shape that is more concavely recessed from side surfaces of the first and second semiconductor chips 100 A and 100 B, as compared to the previous example embodiment.
- the recessed side surface CS′ may further include areas C formed to cover portions of the side surfaces of the first and second semiconductor chips 100 A and 100 B.
- the recessed side surface CS′ may be formed when portions of the non-conductive film 150 in an uncured state that were covering the portions of the side surfaces of the adjacent semiconductor chips 100 A and 100 B in the compression process for pre-bonding are recessed during the hydrostatic bonding process.
- the non-conductive film 150 is not limited to having its entire surface area recessed from the side surfaces of the semiconductor chips 100 A and 100 B, and for example, the non-conductive film 150 may further include a portion protruding from, or remaining atop, the side surfaces of the adjacent semiconductor chip.
- the present inventive concept according to example embodiments may be applied to semiconductor packages in various other forms.
- FIG. 4 is a cross-sectional view illustrating a semiconductor package according to example embodiments.
- a semiconductor package 200 A according to the present example embodiment may have a similar structure to that of the example embodiment illustrated in FIG. 1 except for a heat radiating plate on an uppermost semiconductor chip of the semiconductor chips 100 A to 100 D. Accordingly, the description of the example embodiment illustrated in FIG. 1 may be combined with the description of this particular example embodiment unless otherwise specified.
- the semiconductor package 200 A may include vertically stacked first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, and may further include a heat conducting material layer 210 and a heat radiating plate 220 , sequentially disposed on an upper surface of the fourth semiconductor chip 100 D.
- the heat conducting material layer 210 may be disposed between the heat radiating plate 220 and the fourth semiconductor chip 100 D, and may cover the upper surface of the fourth semiconductor chip 100 D.
- the heat conducting material layer 210 may permit heat generated by the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, to be released to the heat radiating plate 220 more easily.
- the heat conducting material layer 210 may be formed of a thermal interface material (TIM).
- TIM thermal interface material
- the heat conducting material layer 210 may be formed of an insulating material or a material containing an insulating material having electrical insulation properties.
- the heat conducting material layer 210 may include, for example, an epoxy resin.
- Particular examples of the heat conducting material layer 210 may include mineral oil, grease, gap filler putty, phase change gel, phase change material pads, or particle filled epoxy.
- the heat radiating plate 220 may be disposed on the heat conducting material layer 210 .
- the heat radiating plate 220 may be, for example, a heat sink, a heat spreader, a heat pipe, or a liquid cooled cold plate.
- the heat conducting material layer 210 entirely covering the upper surface of the fourth semiconductor chip 100 D may increase the contact area between the fourth semiconductor chip 100 D and the heat conducting material layer 210 , and thus, heat generated by the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be transferred to the heat radiating plate 220 more efficiently.
- FIG. 5 is a cross-sectional view illustrating a semiconductor package according to example embodiments.
- a semiconductor package 200 B may include a similar structure to that of the example embodiment illustrated in FIG. 1 . Accordingly, the description of the example embodiment illustrated in FIG. 1 , unless otherwise specified, may be combined with the description of this particular example embodiment.
- the semiconductor package 200 B may include a base substrate 300 and first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, mounted on the base substrate 300 and sequentially stacked in a direction perpendicular to an upper surface of the base substrate 300 .
- the base substrate 300 may be, for example, a printed circuit board, a ceramic board, or an interposer.
- the base substrate 300 may include a substrate body 310 , a lower surface pad 320 , an upper surface pad 330 , and solder resist layers (not illustrated) formed on a lower surface and an upper surface of the substrate body 310 .
- an internal wiring (not illustrated) may be formed to electrically connect the lower surface pad 320 and the upper surface pad 330 .
- the lower surface pad 320 and the upper surface pad 330 may be portions of circuit wirings exposed by the solder resist layers formed on the lower surface and the upper surface of the substrate body 310 , respectively, the circuit wirings having been patterned on the lower surface and the upper surface of the substrate body 310 covered with Cu foil.
- the base substrate 300 may be an interposer.
- the base substrate 300 may include a substrate body 310 formed of a semiconductor material, and may include the lower surface pad 320 and the upper surface pad 330 formed on the lower surface and the upper surface of the substrate body 310 , respectively.
- the substrate body 310 may be, for example, formed from a silicon wafer.
- an internal wiring (not illustrated) may be formed on the lower surface or the upper surface of the substrate body 310 , or inside the substrate body 310 .
- a through substrate via (not illustrated) may be formed to electrically connect the lower surface pad 320 and the upper surface pad 330 .
- An external connection terminal 340 may be bonded to the lower surface of the base substrate 300 .
- the external connection terminal 340 may be bonded to the lower surface pad 320 .
- the external connection terminal 340 may be, for example, a solder ball or a bump.
- the external connection terminal 340 may electrically connect between the semiconductor package 200 B and an external device.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may all have the same surface area, whereas the base substrate 300 may have a surface area larger than the surface area of each of the first to fourth semiconductor chips 100 A, 100 B, 100 C and 100 D.
- a molding member 180 may be formed to partially or entirely encapsulate the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D.
- the molding member 180 may include, for example, an epoxy mold compound.
- the molding member 180 may be disposed on the base substrate 300 and may have substantially flat coplanar surfaces with side surfaces of the base substrate 300 . Such coplanar side surfaces may be obtained by the same cutting process (please refer to the process in FIG. 12 ).
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be bonded to each other by second non-conductive films (or second adhesive layers) 150 .
- Each of side surfaces CS 2 of the second non-conductive films 150 may be recessed from side surfaces of two corresponding adjacent semiconductor chips of the semiconductor chips 100 A, 100 B, 100 C, and 100 D.
- the side surfaces CS 2 of the second non-conductive films 150 may have concave surfaces.
- a first non-conductive film (or a first adhesive layer) 160 may be disposed between the base substrate 300 and the first semiconductor chip 100 .
- the first non-conductive film 160 may be formed of the same or a similar material as the second non-conductive films 150 .
- the first non-conductive film 160 may be formed of a different material than the second non-conductive films 150 , for example, an underfill material layer.
- the first non-conductive film 160 may be disposed between the base substrate 300 and the first semiconductor chip 100 A to surround side surfaces of first connection bumps 170 A.
- the first non-conductive film 160 may be formed of, for example, an epoxy resin.
- a thickness of the first non-conductive film 160 may be smaller than a thickness of each the non-conductive film 150 .
- the side surface CS 1 of the first non-conductive film 160 has a first recessed depth
- each the side surfaces CS 2 of the second non-conductive film 150 has a second recessed depth.
- the first recessed depth may be different from the second recessed depth.
- FIG. 6 is an enlarged cross-sectional view illustrating region “B” of FIG. 5 .
- FIG. 6 illustrates the first non-conductive film 160 located between the base substrate 300 and the first semiconductor chip 100 A.
- the first non-conductive film 160 due to the base substrate 300 bonded therebelow having a comparatively larger surface area, may be more likely to overflow due to an increased surface tension between the base substrate 300 and the first non-conductive film 160 in an uncured state. Since the base substrate 300 may be used similarly as a carrier substrate during the semiconductor package manufacturing process, the first non-conductive film 160 in an uncured state may flow out onto an upper surface of the base substrate 300 , thereby forming an overhang OH (a portion of the non-conductive film that expands onto the base substrate 300 , as illustrated by the dashed line in FIG. 6 ).
- This overhang OH may covers the upper surface of the base substrate 300 , thereby reducing an area of the base substrate 300 on which the molding member 180 is later formed.
- the reduction in the area of the upper surface of the base substrate 300 may cause defective connection between the molding member 180 and the base substrate 300 , thereby rendering the molding member 180 unable to serve as an appropriate passivation structure.
- the molding member 180 may be lifted or moisture may penetrate the molding member 180 .
- side surfaces of the first non-conductive film 160 may be recessed from between the base substrate 300 and the first semiconductor chip 100 B, through a hydrostatic bonding process for curing the non-conductive films 160 and 150 in uncured states.
- a hydrostatic bonding process for curing the non-conductive films 160 and 150 in uncured states.
- the first and second non-conductive films 160 and 150 in uncured states may be cured under pressure applied by a pressurized fluid in a hydrostatic bonding process, and thus may have side surfaces recessed from side surfaces of adjacent semiconductor chips.
- internal voids present inside the first and second non-conductive films 160 and 150 may be eliminated, and also, the first and second non-conductive films 160 and 150 may become more securely bonded with the connection bumps.
- a secure bond may be achieved by preventing defects due to an overflow of the non-conductive films 160 and 150 in uncured states from being developed and by increasing filling rates of the non-conductive film 150 .
- the concave side surfaces CS 1 and CS 2 of the first and second non-conductive films 160 and 150 may be controlled through controlling processing conditions (for example, temperature, pressure, curing speed, etc.) of the hydrostatic bonding process, and also through controlling the properties, such as viscosity, of the first and second non-conductive films 160 and 150 in uncured states.
- processing conditions for example, temperature, pressure, curing speed, etc.
- properties such as viscosity
- the first and second non-conductive films 160 and 150 in uncured states may have viscosity of about 1,000 Pa ⁇ s or less.
- FIG. 7 is a process flowchart illustrating a method of manufacturing a semiconductor package according to example embodiments.
- a method of manufacturing a semiconductor package according to the present example embodiment may start with preparing a plurality of semiconductor chips having connection bumps and through substrate vias (S 71 ).
- Each of the plurality of semiconductor chips may include, in addition to the connection bumps and the through substrate vias, a semiconductor substrate, a semiconductor device layer, lower connection pads, and upper connection pads. Descriptions of each of these components may be combined with the description of semiconductor chips illustrated in FIG. 1 .
- the plurality of semiconductor chips may be memory chips or logic chips, and in some example embodiments, may include memory chips of the same size.
- the plurality of semiconductor chips may be stacked such that uncured non-conductive films may be disposed between the plurality of semiconductor chips (S 73 ).
- the uncured non-conductive films correspond to the non-conductive films in uncured states described above and may be an example of an uncured adhesive layer.
- the uncured non-conductive film may include an uncured adhesive resin.
- the adhesive resin may include at least one of the thermosetting resins described above.
- the uncured non-conductive film employed in the present example embodiment may have low enough viscosity that permits the uncured non-conductive film to obtain a desired shape (for example, a side surface having a concave surface) during the hydrostatic bonding process.
- the uncured non-conductive film may have viscosity of about 1,000 Pa ⁇ s or less.
- an uncured non-conductive film may be provided on a surface of each semiconductor chip that has connection bumps formed thereon.
- the uncured non-conductive film may be in a partially cured state (that is, at B-stage).
- the uncured non-conductive film to be used in these example embodiments may not be limited to film types.
- the uncured non-conductive film may be applied and used in a paste state.
- the plurality of stacked semiconductor chips may be pre-bonded through thermal compression of the plurality of semiconductor chips (S 75 ).
- the pre-bonding process may be conducted so that the plurality of semiconductor chips remain stacked through a subsequent hydrostatic bonding process.
- the plurality of semiconductor chips may be pre-bonded by exploiting adhesive properties of the non-conductive films.
- an appropriate temperature and/or pressure may be applied to prevent side surfaces of the uncured non-conductive films from protruding.
- a recess process of the non-conductive films obtaining concave side surfaces may be conducted more conveniently in the hydrostatic bonding process.
- the non-conductive films even when portions of the non-conductive films have over-flowed onto the side surfaces of the semiconductor chips, it may still be possible for the non-conductive films to obtain side surfaces in a desired shape, depending on viscosity of the non-cured non-conductive films and/or processing conditions of the hydrostatic bonding process.
- the non-conductive films may be cured by using a pressurized fluid (S 77 ) of the hydrostatic bonding process.
- a hydrostatic pressure of the pressurized fluid and a curing temperature of the uncured non-conductive films may be applied to the stacked semiconductor chips, thereby curing the non-conductive films. More specifically, as illustrated in FIG. 8 , in an example hydrostatic bonding process, the uncured non-conductive films, once heated to a curing temperature thereof, may be immediately subjected to the hydrostatic pressure by the pressurized fluid, and once the uncured non-conductive films are sufficiently cured to form the non-conductive films of FIGS. 1, 4 and 5 , for example, the temperature may be lowered below the curing temperature and the pressure may be released.
- the side surfaces of the uncured non-conductive films may be recessed from the side surfaces of the plurality of semiconductor chips during the curing process as shown in FIG. 8 .
- the present invention is not limited thereto.
- the side surfaces of the uncured non-conductive films may be recessed from the side surfaces of the plurality of semiconductor chips before the curing process, by applying the hydrostatic pressure before applying a temperature above the curing temperature to the semiconductor chips.
- this process may be conducted at a temperature and/or pressure slightly higher than hydrostatic bonding processes.
- the hydrostatic bonding process may be conducted at about 200° C. or greater and about 10 atm or greater (with respect to the maximum point in FIG. 8 ).
- the hydrostatic bonding process may be conducted at about 250° C. and about 15 atm.
- FIGS. 9 to 12 are cross-sectional views illustrating a method of manufacturing a semiconductor package according to example embodiments. The method of manufacturing a semiconductor package will be described with reference to a method of manufacturing a semiconductor package 200 B illustrated in FIG. 5 . FIGS. 9 to 12 will be described with reference to the process flowchart of FIG. 7 .
- FIG. 9 illustrates three stacked semiconductor chips disposed on a base substrate 300 by performing steps S 71 and S 73 of FIG. 7 .
- Each stacked semiconductor chip has a structure in which first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D are sequentially stacked while having uncured first and second non-conductive films 160 ′′ and 150 ′′ disposed therebetween.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D that are singulated from a wafer may be stacked on the base substrate 300 .
- the base substrate 300 may serve as a carrier substrate in a subsequent process.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be semiconductor chips of the same kind (for example, memory chips).
- at least one of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be a different semiconductor (a different memory chip or a logic chip) than the others.
- the first semiconductor chips 100 A singulated from a wafer may be aligned at a uniform distance (D 1 ) on a carrier substrate (not illustrated) by using a semiconductor chip transfer device (not illustrated), and then by using a carrier substrate, the first semiconductor chips 100 A may be transferred onto the base substrate 300 to have connection bumps 170 A positioned on an upper surface pad 330 of the base substrate 300 .
- the uncured first non-conductive film 160 ′′ may be provided on lower surfaces of the first semiconductor chips 100 A and/or upper surfaces of the base substrate 300 , before the first semiconductor chips 100 A are stacked on the base substrate 300 .
- the second to fourth semiconductor chips 100 B, 100 C, and 100 D may be sequentially transferred to thereby provide a stack structure illustrated in FIG. 9 .
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be transferred at a wafer level.
- the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D may be singulated to a desired distance after being transferred on a carrier substrate at the wafer level.
- the distance D 1 may be such a distance that permits the molding member ( 180 in FIG. 2 ) to surround side surfaces of the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, and side surfaces of the first and second non-conductive films 160 and 150 . Since in the subsequent process the uncured non-conductive films 160 ′′ and 150 ′′ may be controlled to be recessed, not protruded, this distance D 1 may be determined to an appropriate size without consideration for overhanging portions of the non-conductive films after being cured (in particular, the first non-conductive film 160 ).
- the first to four semiconductor chips 100 A, 100 B, 100 C, and 100 D in each stacked semiconductor chip may be pre-bonded through thermal compression of the stacked semiconductor chips by performing step S 75 of FIG. 7 .
- the base substrate 300 and the first semiconductor chip 100 A, and the stacked semiconductor chips 100 A, 100 B, 100 C, and 100 D may be in temporarily bonded state during a subsequent process, by the adhesive properties of the first and uncured second non-conductive films 160 ′ and 150 ′ which remain uncured.
- the step S 75 may be conducted under the condition that the first and second uncured non-conductive films 160 ′ and 150 ′ remain uncured.
- an appropriate temperature and/or pressure may be applied during a pre-compression process to prevent the side surfaces of each of the first and second uncured non-conductive films 160 ′ and 150 ′ from being protruded from between two adjacent semiconductor chips of the semiconductor chips 100 A to 100 D.
- the first and second uncured non-conductive films 160 ′ and 150 ′ may be prevented from overflowing onto the side surfaces of adjacent semiconductor chips, thereby allowing the non-conductive films 150 and 160 of FIG. 11 to obtain concave side surfaces in step S 77 of FIG. 7 .
- the stacked semiconductor chips obtained in FIG. 10 may be disposed in a hydrostatic chamber 500 to cure the first and second uncured non-conductive films 160 ′ and 160 ′ by using a pressurized fluid in step S 77 .
- the hydrostatic chamber 500 used in this process may include a sealed inner space with an inlet 510 and an outlet 520 for the pressurized fluid.
- the stacked semiconductor chips may be disposed inside the inner space and heated to a curing temperature of the first and second uncured non-conductive films 160 ′ and 150 ′, and the pressurized fluid may be injected therein to apply the hydrostatic pressure to each of the stacked semiconductor chips.
- a predetermined heat and pressure may be applied to the first and second uncured non-conductive films 160 ′ and 150 ′ and the connection bumps 170 A, 170 B, 170 C, and 170 D, disposed between the base substrate 300 and the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D.
- the first and second uncured non-conductive films 160 ′ and 150 ′ may be cured, thereby enhancing the bond between the semiconductor chips adjacent to the base substrate.
- the connection bumps 170 A, 170 B, 170 C, and 170 D may include an intermetallic compound to lower the contact resistance between upper connection pads 144 located therebelow.
- the hydrostatic bonding process may be conducted at a temperature and/or pressure higher than typical hydrostatic bonding processes.
- the hydrostatic bonding process of step S 77 may be conducted at 200° C. or higher and 10 atm or higher.
- the hydrostatic bonding process may be conducted at about 250° C. and about 15 atm.
- the pre-bonding process of step S 75 may be performed at a temperature below the temperature of the hydrostatic bonding process of step S 77 under a pressure below the pressure of the hydrostatic bonding process of step S 77 .
- the pre-bonding process may be performed at a temperature below a curing temperature of the uncured non-conductive films 160 ′′ and 150 ′′ and the hydrostatic bonding process may be performed at a temperature above the curing temperature.
- this recess process may prevent defects from being developed due to overflow of the first and second uncured non-conductive films 160 ′ and 150 ′, and may achieve a secure bond by increasing filling rates of the first and second non-conductive films 160 and 150 .
- the molding member 180 may be formed to encapsulate the first to fourth semiconductor chips 100 A, 100 B, 100 C, and 100 D, disposed on the base substrate 300 .
- the molding member 180 may be formed to surround the side surfaces of the semiconductor chips 100 A, 100 B, 100 C, and 100 D, and in the present example embodiment, may be formed to cover an upper surface of the semiconductor chip 100 D. Further, the molding member 180 may be formed to surround the side surfaces of the first and second non-conductive films 160 and 150 .
- External connection terminals 340 may be next formed on lower surface pads 320 of the base substrate 300 . The external connection terminals 340 may electrically connect the semiconductor package to an external device. For example, the external connection terminals 340 may be solder balls or bumps in various shapes.
- a cutting process may be conducted (portions denoted by broken lines may be removed) to separate the semiconductor chips 100 A, 100 B, 100 C, and 100 D into a semiconductor package 200 B illustrated in FIG. 5 .
- Side surfaces of the molding member 180 may have substantially flat coplanar surfaces with side surfaces of the base substrate 300 .
- the bonding surface between the molding member 180 and the first and second non-conductive films 160 and 150 may be increased, thereby having an increased bond strength therebetween. Accordingly, the reliability of the semiconductor package may be increased.
- semiconductor packages 200 and 200 A having different structures than the semiconductor package 200 B, may be fabricated without departing from the scope of the present inventive concept.
- the semiconductor packages 200 and 200 A illustrated in FIG. 1 and FIG. 4 may be fabricated in a manner similar to configuring stacks of semiconductor chips by using a separate carrier substrate in place of the base substrate 300 .
- FIG. 13 is a block diagram illustrating a configuration of a semiconductor package according to example embodiments.
- a semiconductor device 1000 may include a microprocessor unit (MPU) 1010 , a memory 1020 , an interface 1030 , a graphics processing unit (GPU) 1040 , function blocks 1050 , and a bus 1060 connecting the MPU 1010 , the memory 1020 , the interface 1030 , the GPU 1040 , and the function blocks 1050 .
- the semiconductor device 1000 may include both the microprocessor unit 1010 and the graphics processing unit 1040 , or may include only one of the two.
- the microprocessor unit 1010 may include a core and an L2 cache.
- the microprocessor unit 1010 may include a multi-core. Individual cores of the multi-core may have the same or different performance characteristics from each other. Individual cores of the multi-core may be activated at the same time or may be activated at different points in time from each other.
- the memory 1020 may store results or the like processed by the function blocks 1050 under the control of the microprocessor unit 1010 .
- the interface 1030 may send data or signals to or receive data or signals from external devices.
- the graphics processing unit 1040 may process graphics functions.
- the graphics processing unit 1040 may perform a video codec or may process 3D graphics.
- the function blocks may perform various functions.
- the semiconductor package 100 is an application processor (AP) used on a mobile device, a portion of the function blocks 1050 may perform a communications function.
- the semiconductor device 1000 may include the semiconductor packages 200 , 200 A, and 200 B as described in FIG. 1 , FIG. 4 , and FIG. 5 .
- a space between packages on a base substrate may be reduced while productivity may be increased, by controlling the problem of non-conductive films (NFC) flowing out from between semiconductor chips (or between the base substrate and a semiconductor chip) through a hydrostatic bonding process. Further, reliability of the packages may be increased by improving bond strength between side surfaces of the non-conductive films and an external molding member.
- NFC non-conductive films
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KR20220162300A (en) | 2021-06-01 | 2022-12-08 | 삼성전자주식회사 | Semiconductor package and method for manufacturing semiconductor package |
WO2022261811A1 (en) * | 2021-06-15 | 2022-12-22 | 华为技术有限公司 | Multi-wafer stack structure and manufacturing method therefor |
KR20230044858A (en) * | 2021-09-27 | 2023-04-04 | 삼성전자주식회사 | Semiconductor package |
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KR102530763B1 (en) | 2023-05-11 |
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CN110943061A (en) | 2020-03-31 |
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